WELDING CONSUMABLES FOR PIPELINE CONSTRUCTION

Editorial

Since BHLER WELDING is one of the pioneer suppliers of arc welding consumables the dedication to sophisticated applications became apparent very soon. So when transport of oil and gas took a greater significance, BHLER WELDING started to engage and take interest in this business. Pipeline construction in different climatic zones and in territories with different conditions of the soil demand from the engineers inventiveness. BHLER WELDING faces this very challenge alongside the prominent pipelaying companies and consequently has achieved a

world leading position in this segment with cellulosic and basic coated electrodes and wires, with weld metal toughness for safety reasons in the focus of attention. BHLER WELDING consumables are world-famous both for onshore pipeline projects and for reeled offshore subsea pipeline laying from barges, because thousands of kilometres of linepipe have already been welded with them. A comprehensive worldwide sales network of well stocked partners ensures rapid and punctual deliveries in all countries. Your nearest sales partner can be found on the Internet www.boehler-welding.com

BHLER WELDING consumables are available in moisture resistant and hermetically sealed packs.

Selection guide

Electrodes
Steel grades API EN CEL BVD Pipe

Wire

FCAW

Low strength pipe steels

API A, B FOX CEL FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 85 FOX EV Pipe

X42 - X52

FOX CEL

FOX EV Pipe FOX EV 60 Pipe

SG 3-P K-Nova Ni

X56 - X60

FOX CEL FOX CEL Mo FOX CEL 75 FOX CEL 85 FOX CEL

FOX BVD RP FOX BVD 85

FOX EV Pipe FOX EV 60 Pipe

SG 3-P K-Nova Ni

EN

L210

FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 85

FOX EV Pipe

L290MB-L360MB

FOX CEL

FOX EV Pipe FOX EV 60 Pipe

SG 3-P K-Nova Ni

L385M-L415MB

FOX CEL FOX CEL Mo FOX CEL 75 FOX CEL 85

FOX BVD RP FOX BVD 85

FOX EV Pipe FOX EV 60 Pipe

SG 3-P K-Nova Ni

High strength pipe steels

API X65 FOX CEL FOX CEL 85 FOX CEL FOX CEL 85 FOX CEL 90 FOX CEL FOX CEL 90 FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 90 FOX EV 60 Pipe SG 3-P K-Nova Ni K-Nova Ni NiMo 1-IG

X70

FOX EV 70 Pipe

X80

FOX BVD RP FOX BVD 90 FOX BVD 100 FOX BVD RP FOX BVD 110 FOX BVD 120

FOX EV 70 Pipe

NiMo 1-IG

X100-X110

EN

L450MB

FOX CEL FOX CEL 85 FOX CEL FOX CEL 85 FOX CEL 90 FOX CEL FOX CEL 90

FOX BVD RP FOX BVD 85 FOX BVD RP FOX BVD 90

FOX EV 60 Pipe

SG 3-P K-Nova Ni K-Nova Ni NiMo 1-IG

L485MB

FOX EV 70 Pipe

L555MB

FOX BVD RP FOX BVD 90 FOX BVD 100

FOX EV 70 Pipe

NiMo 1-IG

Duplex steels
22Cr FOX CN 22/9 N FOX CN 22/9 Nb CN 22/9 N-IG CN 22/9 PW-FD

Selection depends on welding technology, see detailed recommendation for root pass, hot pass and filler layers on next pages. CEL = Cellulose coated electrodes BVD = Basic coated electrodes for vertical down welding Pipe = Basic coated electrodes for vertical up welding FCAW = Flux cored welding wire

BHLER WELDING Consumables for pipeline construction

Overview

Page

Cellulosic electrodes for vertical down welding

Comparison table for pipe steels Recommendations for cellulose coated electrodes BHLER BHLER BHLER BHLER BHLER BHLER BHLER BHLER FOX FOX FOX FOX FOX FOX FOX FOX CEL CEL+ CEL Mo CEL 75 CEL 75 G CEL 85 CEL 85 G CEL 90 (AWS (AWS (AWS (AWS (AWS (AWS (AWS (AWS E6010) E6010) E7010-A1) E7010-P1) E7010-G) E8010-P1) E8010-G) E9010-G)

5 7 8 8 8 9 29 9 29 9 10 - 13 15 16 16 16 17 17 17 18 - 22

Welding technology Basic coated electrodes for vertical down welding Recommendations for basic coated electrodes BHLER BHLER BHLER BHLER BHLER BHLER FOX FOX FOX FOX FOX FOX BVD BVD BVD BVD BVD BVD RP 85 90 100 110 120 (Root pass) (AWS E8018-G) (AWS E9018-G) (AWS E10018-G) (AWS E11018-G) (AWS E12018-G)

Welding technology

Basic coated electrodes for vertical up welding

Recommendations for basic coated vertical up electrodes BHLER FOX EV PIPE BHLER FOX EV 60 PIPE BHLER FOX EV 70 PIPE (AWS E7016-1) (AWS E8016-G) (AWS E9016-G)

24 25 25 25

Consumables for automatic welding and other consumables for pipeline welding

Recommendations for automatic welding with solid wires Wires for automatic pipeline welding Other consumables for pipeline welding

26 27 - 28 29

Comparison table for pipe steels

Steel classifications API 5 L-92 EN 10208-2 DIN 17172

Yield strength minimum ksi N/mm

2

Tensile strength minimum ksi N/mm

2

Elongation minimum %

A L210 StE 210.7 B L245MB StE 240.7 X 42 L290MB StE 290.7 StE 290.7 TM X 46 L320M StE 320.7 StE 320.7 TM X 52 L360MB StE 360.7 StE 360.7 TM X 56 L385M StE 385.7 StE 385.7 TM X 60 L415MB StE 415.7 StE 415.7 TM X 65 L450MB StE 445.7 TM X 70 L485MB StE 480.7 TM X 80 L555MB StE 550.7 TM

30.0 30.4 30.4 35.0 35.5 34.8 42.0 42.0 42.0

207 210 210 241 245 240 289 290 290

48.0 46.4 46.4 60.0 60.2 53.7 60.0 60.2 60.9

331 320 320 413 415 370 313 415 420

28 26 26 23 22 24 23 21 23

46.0 46.4 46.4

317 320 320

63.0 66.7 66.7

434 460 460

22 21 21

52.0 52.2 52.2

358 360 360

66.0 66.7 74.0

455 460 510

21 20 20

56.0 55.8 55.8

386 385 385

71.0 76.9 76.9

489 530 530

20 19 19

60.0 60.2 60.2

413 415 415

75.0 75.4 79.8

517 520 550

19 18 18

65.0 65.3 64.6 70.0 70.3 69.6 80.0 80.5 79.8

448 450 445 482 485 480 550 555 550

77.0 77.6 81.2 82.0 82.7 87.0 90.0 90.6 100.1

530 535 560 565 570 600 620 625 690

18 18 18 18 18 18 18 18 18

BHLER WELDING Consumables for pipeline construction

Vertical down welding using cellulosic electrodes, UAE

A project in Finland

Recommendations for cellulose coated electrodes

Cellulose coated electrodes

Steel grades API FOX CEL FOX CEL S FOX CEL Mo E 7010-A1 E 6010 FOX CEL 75 E 7010-P1 FOX CEL 85 E 8010-P1 FOX CEL 90 E 9010-G

A B X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80
Steel grades EN

L210 L245MB L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB
for root pass welding only for root pass, hot pass, filler passes and capping. The application of FOX CEL or FOX CEL S for the root pass of the high strength steels X 60 / L415MB and upwards is very common however, their use depends upon the individual specifications and conditions. Please also note our remarks Combination technique and welding with one electrode grade on pages 8 and 9.

Due to their high economy cellulose coated electrodes have been in use for decades for the welding of pipe girth welds for pipe steels up to API 5 L X 80. The high effectiveness originates from the both for root passes as well as filler and cover passes. Bigger electrode diameters in the vertical down position with high amperages and fast travel speeds. BHLER WELDING Consumables for pipeline construction

Although BHLER WELDING cellulosic electrodes are designed to produce joint welds with excellent integrity and impact strength, the high hydrogen content of the weld deposit may limit the application with regard to pipe wall thikkness and impact properties required.

Cellulose coated electrodes for vertical down welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals Standard Classification

mm

A EN API

FOX CEL
EN 499:1994 - E 38 3 C 2 1 AWS A5.1-04: E6010 AWS 5.1M-04: E4310

SMAW

C 0.12 Re Si 0.14 Rm Mn 0.5 A5

450 ( 390) N/mm2 520 ( 470-540) N/mm2 26 ( 22) %

2.5 3.2 4.0 5.0

50-90 80-130 120-180 160-210

Av +20C: 110 ( 70) J 0C: 105 J -20C: 95 J -30C: 65 ( 47) -40C: 45 J YS 65000 ( 57000) PSI TS 75000 ( 68000-78000) PSI Elongation on 4d 26 % Impact energy +68F: 81 ( 52) ft-lb +32F: 77 ft-lb -4F: 70 ( 35) ft-lb -22F: 48 ft-lb -40F: 34 ft-lb

TV-D, TV-A, CL, DNV, FI, ISPESL, Statoil, UDT, SEPROZ, PDO, VNIIST

Polarity negative or root pass. Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.

Cellulose-coated electrode for vertical-down welding of large diameter pipelines; suitable for root runs, hot passes, filler and cover layers. Especially recommended for root run welding. Highly economical compared with vertical-up welding. Apart from its excellent welding and gap bridging characteristics FOX CEL offers a weld deposit with outstanding impact strength values and thus offers the benefit of still more safety in field welding of pipelines. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.

S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, P355T1, P235T2-P355T2, L210NB-L415NB, L290MB-L415MB, P235G1TH, P255G1TH. Root pass up to L555NB, L555MB API Spec. 5 L: A, B, X 42, X 46, X 52, X 56. Root pass up to X 80.

FOX CEL+
EN 499:1994 - E 38 2 C 2 1 AWS A5.1-04: E6010 AWS A5.1M-04: E4310

SMAW

C 0.17 Re Si 0.15 Rm Mn 0.6 A5

450 ( 390) N/mm2 520 ( 470-540) N/mm2 26 ( 22) %

2.5 3.2 4.0

50-90 80-130 120-180

Cellulose-coated electrode for vertical-down welding of large diameter pipelines. Especially recommended for root pass welding on D.C. positive polarity in the vertical down and vertical up welding positions. Apart from its good welding and gap bridging characteristics Bhler FOX CEL+ provides a powerful arc that deposites well penetrated, smooth root passes with high travel speeds as well as high safety against the formation of piping or hollow bead and undercut..

Av +20C: 105 ( 70) J 0C: 95 J -20C: 65 ( 47) J -30C: ( 27) J YS 65000 ( 57000) PSI TS 75000 ( 68000-78000) PSI Elongation on 4d 26 ( 22) % Impact energy +68F: 77 ( 52) ft-lb +32F: 70 ft-lb -4F: 48 ( 35) ft-lb -22F: ( 20) ft-lb

Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.

S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, P355T1, P235T2-P355T2, L210NB-L415NB, L290MB-L415MB, P235G1TH, P255G1TH. Root pass up to L555NB, L555MB API Spec. 5 L: A, B, X 42, X 46, X 52, X 56. Root pass up to X 80. S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, L210-L415NB, L290MB-L415MB, P355T1, P235T2-P355T2, P235G1TH, P255G1TH Root pass up to L555MB. API Spec. 5 L: Grade A, B, X 42, X 46, X 52, X 56, X 60. Root pass up to X 80.

FOX CEL Mo
EN 499:1994 E 42 3 Mo C 2 5 AWS A5.5-96: E7010-A1

SMAW

C Si Mn Mo

0.1 Re 480 ( 420) N/mm2 0.14 Rm 550 ( 510-590) N/mm2 0.4 A5 23 ( 22) % 0.5 Av +20C: 100 ( 70) J 0C: 95 J -20C: 85 J -30C: 50 ( 47) J -40C: 42 J YS 70000 ( 61000) PSI TS 80000 ( 74000-85500) PSI Elongation on 4d 23 ( 22) % Impact energy +68F: 74 ( 52) ft-lb +32F: 70 ft-lb -4F: 63 ft-lb -22F: 37 ( 35) ft-lb -40F: 31 ft-lb

3.2 4.0 5.0

80-130 120-180 160-210

TV-D, TV-A, ABS, CL, ISPESL, UDT, SEPROZ, VNIST

Cellulose-coated electrode for vertical-down welding of high strength large diameter pipelines. Highly economical compared with conventional vertical-up welding. Especially recommended for hot passes, filler and cover layers. Besides the excellent weld metal toughness properties it offers easy operation, and a concentrated intensive arc with deep penetration characteristics in order to ensure sound joint welds with good X-ray quality. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.

Polarity negative for root pass. Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.

Cellulose coated electrodes for vertical down welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals Standard Classification

mm

A EN API

FOX CEL 75
EN 499:1994 - E 42 3 C 2 5 AWS A5.5-96: E7010-P1

SMAW

C 0.14 Re Si 0.14 Rm Mn 0.7 A5

480 ( 420) N/mm2 550 (510-610) N/mm2 23 ( 22) %

3.2 4.0 5.0

80-130 120-180 160-210

TV-A, CL, FI, UDT

Av +20C: 100 ( 85) J 0C: 95 J -20C: 85 J -30C: 55 ( 47) J -40C: 45 ( 27) J YS 70000 ( 61000) PSI TS 80000 ( 74000-89000) PSI Elongation on 4d 23 ( 22) % Impact energy +68F: 74 ( 63) ft-lb +32F: 70 ft-lb -4F: 63 ft-lb -22F: 41 ( 35) ft-lb -40F: 33 ( 20) ft-lb

Polarity negative for root pass. Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.

Cellulose-coated electrode for vertical-down welding of high strength large diameter pipelines. Especially recommended for hot passes, filler and cover layers. Highly economical compared with conventional verticalup welding. The penetrating arc characteristics and the low slag formation allow good bead control and ensure best performance in all positions even with the larger diameter electrodes and high amperages. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.

S235JR, S275JR, S235J2G3, S275J2G3, S355J2G3, P235GH, P265GH, L210-L415NB, L290MB-L415MB, P355T1, P235T2-P355T2, P235G1TH, P255G1TH. Root pass up to L480MB. API Spec. 5 L: Grade A, B, X42, X 46, X 52, X 56, X 60. Root pass up to X 70.

FOX CEL 85
EN 499:1994 E 46 4 1Ni C 2 5 AWS A5.5-96: E8010-P1

SMAW

C Si Mn Ni

0.14 Re 0.1 Rm 0.7 A5 0.6 Av +20C: 0C: -20C: -40C:

490 ( 460) N/mm2 570 (550-650) N/mm2 23 ( 20) % 110 105 100 70 ( 80) J J J ( 47) J

3.2 4.0 5.0

80-130 120-180 160-210

TV-D TV-A ABS, CL, FI, GdF, ISPESL, UDT, SEPROZ, PDO

Cellulose-coated electrode for vertical-down welding of high strength large diameter pipelines. Highly economical compared with conventional vertical-up welding. Especially recommended for hot passes, filler and cover layers. Without doubt BHLER FOX CEL 85 is the most popular cellulosic electrode which meets all the exacting demands of the field welding of cross country pipelines extremely well. It ensures highest joint weld qualitydown to temperatures of -40 C. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too. Cellulose-coated electrode for vertical-down welding of high strength large diameter pipelines. Highly economical compared with conventional vertical-up welding. Especially recommended for hot passes, filler and cover layers. The special design of the coating and the core wire guarantees the highest metallurgical quality and soundness of the weld metal deposit with excellent mechanical properties. The electrode allows good weld pool visability, and easy manipulation in all positions, as well as high safety margins against porosity and slag inclusions.

L415NB-L485NB, L415MB-L485MB. API Spec. 5 L: X 56, X 60, X 65, X 70

Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.

YS 71000 ( 67000) PSI TS 82000 ( 80000-94000) PSI Elongation on 4d 23 ( 20) % Impact energy +68F: 81 ( 59) ft-lb +32F: 77 ft-lb -4F: 74 ft-lb -40F: 52 ( 35) ft-lb

FOX CEL 90
EN 499:1994 E 50 3 1Ni C 2 5 AWS A5.5-96: E9010-G

SMAW

C Si Mn Ni

0.17 Re 610 ( 530) N/mm2 0.15 Rm 650 (620-720) N/mm2 0.9 A5 21 ( 18) % 0.8 Av +20C: 100 ( 80) J 0C: 90 J -20C: 75 J -30C: 65 ( 47) J -40C: 40 ( 27) J YS 89000 ( 77000) PSI TS 94000 ( 90000-104400) PSI Elongation on 4d 21 ( 18) % Impact energy +68F: 74 ( 59) ft-lb +32F: 66 ft-lb -4F: 55 ft-lb -22F: 48 ( 35) ft-lb -40F: 30 ( 35) ft-lb

4.0 5.0

120-180 160-210

TV-D, TV-A, CL, GdF, ISPESL, Statoil, UDT, SEPROZ, VNIIST

L450MB, L485MB, L555MB. API Spec. 5 L: X 65, X 70, X 80

Re-drying: not allowed For preheating, interpass temperature and welding procedure note our recommendations on pages 10 and 11.

BHLER WELDING Consumables for pipeline construction

Welding technology

Preheating and interpass temperature

In order to prevent hydrogen induced cracks it is neccessary to preheat the pipes before commencing welding and to maintain an interpass temperature during welding of the individual beads. In respect of the quite often difficult site conditions a preheating of 150 C (300 F) general is recommended. This covers all wall thicknesses up to 25 mm (1") and weld metals up to class E9010 (FOX CEL 90). When welding thin walled pipes be aware that lower preheating and interpass temperatures are applicable. The attached diagram features the lowest possible temperatures in dependence on the wall thickness and type of electrode.
minimum in C 180 160 140 120 100 80 60 40 20 0 5 wall thickness in mm 10 15 20 25 E9010 E8010 E7010 E6010 minimum in F 356 320 284 248 212 176 140 104 68 32

Recommended joint preparation

60 1.5 - 2.0 1/16 - 5/64 inch) 2/3 1/3

Wall thicknesses 20 mm ( 3/4 inch)

1 - 1.5 (3/64 - 1/16 inch) 1.5 - 2. (1/16 - 5/64 in

10

30

Wall thicknesses > 20 mm (> 3/4 inch)

1.5 (1/16 inch)

Welding technique Stringer bead or root pass

With pipes positioned and held in true alignment with line-up clamps, the stringer bead or root pass is welded. For pipe diameters over 200 mm (8"), it has become general practice to have two welders work on opposite sides of the pipe. Even three or four welders may work simultaneously in order to reduce distortion and maintain uniform gap width. Three to four welders are employed for executing the root pass in pipe of more than 700 mm (28") diameter or on difficult ground. For this most important part of the weld which requires perfect penetration, electrode diameter, travel rate and amperage should be chosen to match pipe diameter and wall thickness. For pipe diameters up to about 250 mm (10") and wall thicknesses up to 8 mm (5/16"), we recommend to use 3.2 mm (1/8") diameter electrodes, for larger sizes, 4 mm (5/32") diameter electrodes. Welding proceeds vertical down, with the electrode being held to maintain good contact with the bevel faces. The procedure recommended is electrode negative. Electrode diameter: 2.5 mm (3/32") 3.2 mm (1/8") 4 mm (5/32")

Welding machines
Cellulose coated electrodes can only be operated on direct current. Welding machines must have a drooping characteristic and high open circuit voltage. In manual arc welding, the distance between the electrode and the weld pool or joint faces, respectively, can hardly be kept constant, i.e. the length of the arc will vary and so will the amperage. The use of welding machines with drooping characteristics minimizes these variations. The open circuit voltage must exceed 70 V in order to provide the high ionization energy required for dissociation of the constituents making up the coating of the electrode. Generators used for welding with cellulose pipeline electrodes usually have an open circuit voltage in the range of 80 to 100 V. Larger electrode diameters require high amperages as well as high voltages, which the generators must deliver during welding. These requirements must be fulfilled by welding machines in general; other details, such as type and mode of operation, may vary for different makes, and will be supplied by the manufacturer.

50 - 180 A 80 - 100 A 120 - 150 A

Line-up clamps should be removed only after completing the root pass over the whole circumference and, in welding larger diameter pipe, only after completing the hot pass. While executing this pass, do not move pipes in order to avoid the risk of crack formation.
80-90

root pass (stringer bead) welding root pass stringer bead 2.5, 3.2 or 4.0 mm 80-90 80-90

10

Cellulose coated electrodes

Hot pass
Slight grinding of the stringer bead surface with rotating steel wire brushes prevents lateral slag inclusions (showing up as waggon tracks in weld radiographs). For welding the hot pass, the electrode is held almost vertical, high amperage being used with the electrode connected to the positive terminal. Electrode sizes commonly used are: 4 mm (5/32") 5 mm (3/16") with 150 - 180 A with 170 - 210 A

avoid porosity. ln the cover pass, porosity is mostly due to overheating of the weld deposit or excessive weaving.
80-90

filler passes

4.0, 5.0 or 5.5 mm

welding of filler and cover passes

60-70 cover pass (cap) 4.0, 5.0 mm 80-90

The high current causes deep penetration which will make any remaining slag inclusions float to the surface and ensure that the root pass is annealed thoroughly. The hot pass should be welded immediately following deposition of the stringer bead, but in no case more than 10 minutes later. This is of special importance for high strength line pipe grades to avoid under bead cracking in the base material.
80-90

Combination technique and welding with one electrode grade

The weld deposit of the root pass which has not been tempered by application of the hot pass may have a strength which is 100 to 150 N/mm2 (~18000 psi) above that of the finished joint. This, and the notch-sensitive shape of the stringer bead may, in case of uncontrolled pipe movement during the welding operation, cause mechanical crack formation before the hot pass is deposited. The combination weld technique which has been recommended and practised successfully for years is an excellent method of avoiding this risk. The combination technique involves welding the stringer bead in higher carbon, higher strength steels with an electro de of lower strength compared to that of the base metal, but giving better ductility (FOX CEL). A comparatively soft and tough stringer bead will absorb mechanical stresses better while it is being welded and before the hot pass is applied. The combination technique has proved highly satisfactory for higher carbon steels, in particular. In spite of its lower strength level, the electrode used for stringer bead welding is compensated in strength due to about 50 % dilution with the base metal. In welding low carbon, reduced pearlite steels, however, the high dilution of the root pass will reduce the strength in this part of the joint. In thin wall pipe, the stringer bead cross section constitutes a larger percentage of the overall pipe cross section than in heavy wall pipe. This may account for additional reduction in strength over the whole cross section. Therefore, we recommend using one electrode grade for all passes, from stringer bead to cap, in line pipe from reduced pearlite steels with less than 0.10 % carbon, having wall thickness below 10 mm (13/32"). Mechanical properties of this electrode grade should equal those of the base metal.

hot pass welding hot pass 2.5, 3.2 or 4.0 mm 80-90 40-50

Filler passes
Beads will be sufficiently flat, and free from undercut and slag inclusions, if the electrode is applied with a slight circular or stepping motion, especially in positions 12 to 2 o'clock, 12 to 10 o'clock, 4 to 6 o'clock and 8 to 6 oclock. Weaving is recommended for all other positions. Rotating steel wire brushes are used to remove slag carefully after each pass. Selection of electrode diameter depends on pipe diameter and wall thickness. Electrode sizes and amperages recommended for filler pass welding on positive (+) polarity: 4 mm (5/32") 120 - 150 A 5 mm (3/16") 160 - 210 A 5.5 mm (7/32") 200 - 260 A Vertical down welding will yield bead thicknesses varying for different pipe welding positions. Therefore, prior to welding the cover pass, it is usually necessary to apply stripper passes on those parts of the pipe circumference where thickness must be corrected. Stripper passes are applied in a relatively fast movement, in positions 2 to 4 o'clock and 10 to 8 o'clock.

Storage
The coating of cellulose electrodes has a relatively high content of moisture which is necessary for the welding characteristics and metallurgical properties of the deposit. In open, unprotected storage, air humidity and/or temperature may reduce or increase the moisture content considerably. Therefore, BHLER cellulose electrodes are packed in cans. Electrodes should be kept in closed storage where prolonged exposure to solar radiation and excessive variations in temperature can be avoided. Once a can has been opened, the electrodes should be used up as soon as possible. Rebaking of cellulose electrodes is not permitted. 11

Cover pass or cap

The cover pass is executed with a slight weaving of the electrode. The weld should not overlap the groove edge by more than 1.5 mm (1/16"). If the cover pass is applied correctly, weld reinforcement is about 1 to 2 mm (1/16"). For this pass, electrode diameter usually is 5 mm (3/16"), with amperage slightly lower than for filler passes (150-200 A) in order to BHLER WELDING Consumables for pipeline construction

Welding technology

Trouble shooting

Defects

Causes

How to avoid defects

Porosity visible on the surface

excessive and uncontrolled weaving base metal overheated (increased risk in thin wall pipe) moisture content of electrode coating too low delayed deoxidation process in weld deposit moisture content in electrode coating too low or too high

weaving not to exceed 2 X electrode dia. choose electrode dia. and amperage as a function of pipe wall thickness keep electrodes in closed containers see Chapter on page 13 storage avoid excessive upsetting of metal deposited see Chapter on page 13 storage

Pinholes not visible on the surface

Piping or hollow beat almost exclusively in the reinforcement of stringer bead - therefore, practically no reduction of cross section

root gap too narrow: degassing hindered by excessive dilution chemical composition of base metal: high Al levels usually favour piping formation insufficient cleaning in between passes stringer bead poorly ground incorrect electrode manipulation amperage too low

root gap width not less than 1 mm the optimum root gap width of 1.5 mm should be observed for 0.040 % Al steels in particular. If trouble continues, use smaller electrode dia. clean each layer with rotary wire brush grind stringer bead sufficiently before applying hot pass improve electrode manipulation increase amperage choose amperage to match electrode dia. and welding position clean groove faces properly

Slag inclusions generally occuring in groove faces and in stringer bead area (waggon tracks)

Lack of fusion (cold shuts)

insufficient melting of groove faces amperage too low groove faces contaminated and/or oxidized

Underbead cracks almost exclusively in the hardened HAZ

combined action of hydrogen, stresses, hardened structure

preheat pipe material to favour hydrogen effusion, increase of heat input is also advantageous avoid moving pipe string considerable hardening is to be expected during welding of the stringer bead, therefore the hot pass must be applied immediately after its completion avoid moving pipe particularly during welding of stringer bead refer to relevant standards and specifications for maximum offset which, however, should be kept to a minimum

Cracks caused by mechanical stresses usually in the stringer bead region

moving of pipe string during welding of stringer bead and/or before applying hot pass edge offset too great, resulting in reduced root cross section and incrcased risk of crack formation

Undercut in the region of stringer bead and cover passes

amperage too high incorrect manipulation

selection of correct amperage to match electrode size

Excess reinforcement

Incorrect manipulation

select amperage to match joint width allowance for desired cover pass weld reinforcement is to be made already when applying last filler pass (e.g. by additional layers or grinding of filler layers that are too high)

Sagging stringer bead

amperage too high poor joint preparation, root gap too large

select correct amperage to match joint preparation for stringer bead

Striking marks

striking right or left of the joint causes local hardening risk of hardening cracks

strike arc in the groove

12

Cellulose coated electrodes

Consumption rate
Diameter Root pass Hot pass Filler + Cap 0,25 inch 0,312 inch 0,432 inch 6,35 mm 7,92 mm 10,97 mm

Wall thickness
0,5 inch 0,562 inch 0,625 inch 0,719 inch 0,812 inch 0,938 inch 12,7 mm 14,27 mm 15,88 mm 18,26 mm 20,62 mm 23,83 mm 1.0 inch 1,062 inch 1,188 inch 25,4 mm 26,97 mm 30,15 mm

10 3/4" 273 mm 12 3/4" 323,8 mm 14" 355,6 mm 16" 406,4 mm 18" 457,2 mm 20" 508 mm 22" 558,8 mm 24" 609,6 mm 26" 660,9 mm 28" 711,2 mm 30" 762 mm 32" 812,8 mm 34" 863,6 mm 36" 914,4 mm 38" 965,2 mm 40" 1016 mm 42" 1066,8 mm 44" 1117,6 mm 46" 1168,4 mm 48" 1219,2 mm 50" 1270 mm 56" 1422,4 mm 60" 1524 mm

Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C Rp Hp F+C

9,5 8,9 25 11 10,6 28,3 12,5 11,7 31,3 14,3 13,4 36,3 16,2 15,1 39,8 18 16,9 44,8 19,9 18,6 49,9 21,7 20,3 53,3 23,6 22,1 58,3 25,4 23,8 61,7 27,3 25,5 68,6 29,1 27,2 71,9 31 29 75,2 32,8 30,7 80,3

9,1 8,8 42,6 11 10,5 51,2 12,1 11,6 55,8 13,9 13,3 62,6 15,7 15 71,2 17,5 16,8 78,1 19,3 18,5 86,6 21,1 20,2 95,1 22,9 22 102 24,7 23,7 110,5 26,5 25,4 117,3 28,3 27,1 125,9 30,1 28,9 134,5 32 30,6 141,3 33,8 32,3 149,9 35,6 34 156,7 37,4 35,8 165,2 39,2 37,5 172 41 39,2 180,6 42,8 41 189,1 44,6 42,7 196 50 47,9 219,9 53,6 51,3 221,4

8,9 8,5 86,3 10,7 10,3 103,6 11,9 11,4 113,5 13,7 13,1 129 15,5 14,8 146,3 17,3 16,5 161,7 19,1 18,3 179 20,9 20 194,4 22,7 21,8 211,7 24,5 23,5 227,2 26,3 25,2 242,7 29,1 26,9 259,9 29,9 28,7 275,4 31,7 30,4 292,6 33,5 32,1 308,1 35,3 33,8 325,4 37,2 35,6 340,8 39 37,3 356,3 40,8 39 372,6 42,6 40,8 389,1 44,4 42,5 406,3 49,8 47,7 454,5 53,4 51,1 471,7

8,8 8,4 114,4 10,6 10,2 138,5 11,7 11,2 153,6 13,5 13 174,3 15,4 14,7 196,8 17,2 16,4 219,2 19 18,2 241,7 20,8 19,9 264,1 22,6 21,6 284,8 24,4 23,3 307,2 26,2 25,1 329,7 28 26,8 352,1 29,8 28,5 374,6 31,6 30,3 395,3 33,4 32 417,7 35,2 33,7 440,1 37 35,5 462,6 38,8 37,2 483,3 40,6 38,9 505,7 42,4 40,6 528,1 44,3 42,4 550,6 49,7 47,6 616,1 53,3 51 643,7

8,7 8,3 147,6 10,5 10,1 175,2 11,6 11,1 193,8 13,4 12,9 221,4 15,2 14,6 249 17 16,3 276,7 18,9 18,1 306,1 20,7 19,8 333,7 22,5 21,5 361,3 24,3 23,2 388,9 26,1 25 418,3 27,9 26,7 446 29,7 28,4 473,7 31,5 30,2 501,3 33,3 31,9 527,2 35,1 33,6 558,3 36,9 35,3 585,9 38,7 37,1 613,6 40,5 38,8 641,2 42,3 40,5 670,6 44,1 42,3 698,3 49,6 47,5 781,1 53,2 50,9 817,4

8,6 8,2 182,5 10,4 9,9 217,1 11,5 11 239,1 13,3 12,8 273,6 15,1 14,5 308,3 16,9 16,2 342,8 18,7 17,9 377,4 20,5 19,7 412 22,4 21,4 448,2 24,2 23,1 482 26 24,9 517,5 27,8 26,6 552,1 29,6 28,3 586,6 31,4 30 621,2 33,2 31,8 655,8 35 33,5 690,4 36,8 35,2 725 38,6 37 759,5 40,4 38,7 794,1 42,2 40,4 830,4 44 42,2 865,1 49,4 47,3 968,8 53,1 50,8 1015,3

8,4 8,1 240,1 10,2 9,8 284,7 11,3 10,9 314 13,2 12,6 360,4 15 14,3 405,8 16,8 16,1 452,4 18,6 17,8 497,5 20,4 19,5 544,2 22,2 21,3 589,1 24 23 635,9 25,8 24,7 680,8 27,6 26,4 727,6 29,4 28,2 772,6 31,2 29,9 819,3 33 31,6 864,3 34,8 33,3 911 36,6 35,1 956 38,4 36,8 1002,8 40,2 38,5 1047,7 42,1 40,3 1094,5 43,9 42 1141,1 49,3 47,2 1277,9 52,9 50,6 1341,8

8,3 7,9 171 10,1 9,6 210,8 11,2 10,7 232,8 13 12,5 267,4 14,8 14,2 291,6 16,8 15,9 324,3 18,4 17,6 357,2 20,2 19,4 391,8 22,1 21,1 424,6 23,8 22,8 457,5 25,7 24,6 490,4 27,5 26,3 524,9 29,3 28 557,8 31,1 29,7 590,6 32,9 31,5 623,5 34,7 33,2 656,3 36,5 34,9 690,8 37 35,4 723,2 10,1 38,4 756,6 41,9 40,1 1001,1 43,7 41,9 1042,6 49,1 47 1168,9 52,7 50,5 1229,4

8 7,7 230,5 9,8 9,4 350 10,9 10,5 386 12,8 12,2 443,1 14,6 13,9 500,2 16,4 15,7 557,4 17,6 16,8 594 20 19,1 671,6 21,8 20,9 730,4 23,6 22,6 785,8 25,4 24,3 843 27,2 26 901,9 29 27,8 959 30,8 29,5 1016,1 32,6 31,2 1073,3 34,4 33 1130,4 36,2 34,7 1187,5 38 36,4 1244,7 39,9 38,2 1301,9 41,7 39,9 1359 43,5 41,6 1417,8 48,9 46,8 1589,2 52,5 50,3 1674
10

7,9 7,6 258,5 9,7 9,3 391,8 10,5 10 418,6 12,2 11,7 480,5 14 13,4 544,1 15,7 15 606,1 17,5 16,7 669,7 19,2 18,4 731,6 21 20,1 795,2 22,7 21,7 857,1 24,4 23,4 919,1 26,2 25,1 981,1 27,9 26,7 1044,7 29,7 28,4 1106,6 31,4 30,1 1170,2 33,2 31,8 1232,1 34,9 33,4 1294 37,9 36,3 1404,5 38,4 36,8 1419,6 41,5 39,8 1532,7 43,4 41,5 1598,4 48,8 46,7 1792,4 52,4 50,2 1887,6
1.5 - 2 (1/16 - 5/64 inch)

7,8 7,5 289,8 9,6 9,2 438,9 10,7 10,3 483,6 12,5 12 556,3 14,3 13,7 629 16,1 15,5 701,8 18 17,2 774,6 19,9 18,9 847,3 21,6 20,7 919,9 23,4 22,4 991,1 25,2 24,1 1063,8 27 25,8 1136,6 28,8 27,6 1209,3 30,6 29,3 1282 32,4 31 1354,8 34,2 32,8 1427,5 36 34,5 1500,3 37,8 36,2 1572,9 39,6 37,9 1591,8 41,4 39,7 1718,5 43,2 41,4 1789,5 48,7 46,6 2007,8 52,3 50 2115,1

7,6 7,2 354,5 9,4 9 538,3 10,2 9,7 586,9 11,9 11,4 675,6 13,6 13,1 747,6 15,4 14,7 834,8 17,1 16,4 921,9 18,9 18,1 1003,3 20,6 19,8 1096,1 22,4 21,4 1181,5 24,1 23,1 1269,9 25,9 24,8 1347,9 27,6 26,4 1434,4 29,4 28,1 1519,8 31,1 29,8 1606,8 32,8 31,5 1692,3 34,6 33,1 1779,3 37,6 36 1939,5 38,1 36,5 1962 41,2 39,5 2119,7 43 41,2 2209,8 48,4 46,4 2478,4 52 49,8 2613,5

60 1.5 (1/16 inch) 30

Electrode consumption in kg Electrode weight for cellulosic electrodes. Calculation for 100 joints without wastage. Stub end loss 50 mm (2 inches).

1.5 (1/16 inch)

1.5 (1/16 inch)

1/3

2/3

BHLER WELDING Consumables for pipeline construction

13

BTC (Baku Tbilisi Ceyhan) Crude Oil Pipeline Project, Aserbeijan, Georgia, Turkey 2004

14

Recommendations for basic coated electrodes

Basic coated electrodes

Steel grades API FOX BVD E 8018-G FOX BVD 85 E 8018-G FOX BVD 90 E 9018-G FOX BVD 100 E 10018-G FOX BVD 110 E 11018-G

A B X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80 X 100
Steel grades EN

L210 L245MB L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB
for root pass welding only for filler passes and capping

Basic coated vertical down electrodes are characterized by their favourable mechanical and technological features and by their low hydrogen contents (HD < 5 ml/100 g). Welding time is the same in comparison with filler and cover passes as for welding using cellulose coated electrodes. However, there are losses in economy when welding root passes. It is therefore recommended that root and hot passes be welded with cellulose coated electrodes and the filler and cover passes with BHLER WELDING Consumables for pipeline construction

basic coated vertical down electrodes. Low hydrogen vertical down electrodes are used in the welding of thick walled joints and for the welding of steels like API X 80 or X 100 as well as for the welding of joints with high impact strength requirements. A further field of application is in above ground installation (AGI) and pipe laying tasks (e.g. Iandfall sections), where the use of cellulose coated electrodes is prohibited. 15

Basic coated electrodes for vertical down welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals Standard Classification

mm

A EN API

FOX BVD RP
EN 499:1994 E 46 3 B 4 1 H5 AWS A5.5-96: E8018-G

SMAW

C 0.05 Re Si 0.3 Rm Mn 1.0 A5

510 ( 460) N/mm2 560 (550-650) N/mm2 26 ( 22) %

2.5 3.2

80-110 100-160

TV-D, UDT, SEPROZ

Av +20C: 170 ( 130) J 0C: 150 J -20C: 120 J -30C: 60 ( 47) J YS 74000 ( 67000) PSI TS 81200 ( 80000-94000) PSI Elongation on 4d 26 ( 22) % Impact energy +68F: 125 ( 96) ft-lb +32F: 111 ft-lb -4F: 89 ft-lb -22F: 44 ( 35) ft-lb

Basic coated electrode for verticaldown welding of root passes in pipeline construction and structural work. Also suitable for vertical- up welding of root passes. The deposit is extremely crack resistant and features high toughness and a very low hydrogen content (HD<5ml/100g). Highly economical compared with conventional verticalup welding. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSCtest are available too.

Root passes for following steels: S235J2G3 up to S355J2G3, L290NB up to L415NB, L290MB up to L555MB, P235GH up to P310GH API Spec. 5 L: Root passes for following steels: X 42, X 46, X 52, X 56, X 60, X 70, X 80

Re-drying if necessary: 300-350 C, min. 2 h. Note our recommendations on pages 18 and 22.

FOX BVD 85
EN 499:1994 E 46 5 1Ni B 4 5 H5 AWS A5.5-96: E8018-G

SMAW

C Si Mn Ni

0.04 Re 0.4 Rm 0.9 A5 0.9 Av +20C: 0C: -20C: -40C: -50C:

510 ( 460) N/mm2 560 (550-650) N/mm2 27 ( 22) % 170 150 120 85 65 ( 130) J J J ( 60) J ( 47) J

3.2 4.0 4.5

110-160 180-210 200-240

TV-D, CL, GdF, UDT, SEPROZ

Re-drying if necessary: 300-350 C, min. 2 h. Note our recommendations on pages 18 and 22.

YS 74000 ( 67000) PSI TS 81200 ( 80000-94000) PSI Elongation on 4d 27 ( 22) % Impact energy +68F: 125 ( 96) ft-lb +32F: 111 ft-lb -4F: 89 ft-lb -40F: 63 ( 45) ft-lb -58F: 48 ( 35) ft-lb

Basic coated electrodes for verticaldown welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content (HD<5ml/100g). Deposition rate is 80-100 % higher than for vertical up welding. The weld deposit of BHLER FOX BVD 85 shows an ideal combination between high strength and cryogenic toughness down to -50 C (-58 F). Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. It can be used in sour gas applications (HIC-Test acc. NACE TM-02-84). Test values for SSC-test are available too.

S235J2G3 up to S355J2G3, L290NB up to L450NB, L290MB up to L450MB, P235GH up to P295GH API Spec. 5 L: A, B, X 42, X46, X 52, X 56, X 60, X 65

FOX BVD 90
EN 757:1997 E 55 5 Z2Ni B 4 5 H5 AWS A5.5-96: E9018-G

SMAW

C Si Mn Ni

0.04 Re 0.3 Rm 1.2 A5 2.2 Av +20C: 0C: -20C: -40C: -50C:

600 ( 550) N/mm2 650 (620-720) N/mm2 27 ( 20) % 170 145 130 110 80 ( 120) J J J J ( 47) J

3.2 4.0 4.5

110-160 180-210 200-240

TV-D, CL, Statoil, UDT, GdF, SEPROZ

Re-drying if necessary: 300-350 C, min. 2 h. Note our recommendations on pages 18 and 22.

YS 87000 ( 80000) PSI TS 94000 ( 90000-104000) PSI Elongation on 4d 27 ( 20) % Impact energy +68F: 127 ( 89) ft-lb +32F: 107 ft-lb -4F: 96 ft-lb -40F: 82 ft-lb -58F: 60 ( 35) ft-lb

Basic coated electrodes for vertical down welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content (HD<5ml/100 g). Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. Deposition rate is 80-100 % higher than for vertical up welding.

L485MB, L555MB API Spec. 5 L: X 70, X 80

16

Basic coated electrodes for vertical down welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals Standard Classification

mm

A EN API

FOX BVD 100

EN 757:1997 E 62 5 Z2Ni B 4 5 H5 AWS A5.5-96: E10018-G

SMAW

C Si Mn Ni

0.07 Re 0.4 Rm 1.2 A5 2.3 Av +20C: 0C: -20C: -50C:

670 ( 620) N/mm2 730 (690-810) N/mm2 24 ( 18) % 150 125 120 70 ( 110) J J J ( 47) J

4.0 4.5

180-210 200-240

TV-D, UDT, SEPROZ

Re-drying if necessary: 300-350 C, min. 2 h. Recommended interpass temperature > 100 C. Note our recommendations on pages 18 and 22.

YS 97000 ( 90000) PSI TS 105800 (100000-117000) PSI Elongation on 4d 24 ( 18) % Impact energy +68F: 111 ( 81) ft-lb 32F: 92 ft-lb -4F: 89 ft-lb -58F: 52 ( 35) ft-lb

Basic coated electrodes for vertical down welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content (HD <5 ml/100 g). Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. Deposition rate is 80-100 % higher than for vertical up welding.

L555MB API Spec. 5 L: X 80

FOX BVD 110

EN 757:1997 E 69 3 Mn2NiMo B 4 5 H5 AWS A5.5-96: E11018-G

SMAW

C Si Mn Ni Mo

0.07 0.4 1.5 2.0 0.3

Re Rm A5 Av +20C: -20C: -40C:

720 ( 690) N/mm2 810 ( 760) N/mm2 20 ( 17) % 90 ( 80) J 70 ( 50) J 50 ( 40) J

4.0 4.5

180-210 200-240

SEPROZ

Re-drying if necessary: 300-350 C, min. 2 h. Recommended interpass temperature > 110 C. Note our recommendations on pages 18 and 22.

YS 104000 ( 100000) PSI TS 117000 ( 110000) PSI Elongation on 4d 20 ( 17) % Impact energy +68F: 66 ( 60) ft-lb -4F: 52 ( 37) ft-lb -40F: 37 ( 30) ft-lb

Basic coated electrodes for verticaldown welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content (HD <5 ml/100 g). Special design and development work has enabled this electrode to provide exceptional striking characteristics and the avoidance of start porosity on cover (cap) passes. Due to this and the good welding characteristics this special basic electrode offers easy handling even under field conditions. Deposition rate is 80-100% higher than for vertical up welding.

L6901) API Spec. 5 L: X1001)

1)

not standardised yet

FOX BVD 120

EN 757:1997 E 69 3 Mn2NiMo B 4 5 H5 AWS A5.5-96: E12018-G

SMAW

C Si Mn Ni Mo

0.07 0.4 1.85 2.25 0.35

Re Rm A5 Av +20C: -20C: -40C:

815 ( 740) N/mm2 870 ( 830) N/mm2 18 ( 17) % 80 ( 80) J 60 ( 50) J 50 ( 40) J

3.2 4.0

110-160 180-220

Re-drying if necessary: 300-350 C, min. 2 h. Recommended interpass temperature > 120 C. Note our recommendations on pages 18 and 22.

YS 118000 ( 107300) PSI TS 126000 ( 120300) PSI Elongation on 4d 18 ( 17) % Impact energy +68F: 60 ( 60) ft-lb -4F: 44 ( 37) ft-lb -40F: 37 ( 30) ft-lb

Basic coated electrodes for verticaldown welds of large diameter pipelines and for structural work. Suitable for filler and cover pass welding in pipeline construction. Deposit is extremely crack resistant, and features high toughness and a very low hydrogen content (according AWS condition HD<4ml/100 g). Deposition rate is 80-100 % higher than for vertical up welding. This stick electrode is optimised for best striking properties and for avoiding start porosity in the cap layer. With its excellent welding properties the electrode offers easy handling also under difficult conditions.

L6901) API Spec. 5 L: X1001), X1101)

1)

not standardised yet

BHLER WELDING Consumables for pipeline construction

17

Welding technology

Interpass Temperature
The interpass temperature influences the metallurgical processes that take place in the deposit during solidification and cooling and thus to a certain extent also the mechanical properties of the weld metal. It is thus generally recommended that the interpass temperature be maintained at approx. 100 C 30 C (210 F 86 F) throughout welding.

Welding machines
For welding pipe girth welds in pipeline construction, the basic coated vertical down electrodes can only be operated on direct current and positive polarity. Practical experience has shown that welding machines usually used for the welding of cellulose coated electrodes in pipe-line construction are also suitable for the welding of basic coated vertical down electrodes. The welding machines should have a drooping characteristic and a high open circuit voltage.

60 30 0-1 (3/64 inch)

0 - 1 (3/64 inch)

Recommended joint preparation

Wall thicknesses 20 mm ( 3/4 inch)

10

2/3

Wall thicknesses 20 mm ( 3/4 inch)

2 - 3 mm (5/64 - 1/8 inch)

2 - 3 mm (5/64 - 1/8 inch)

Preheating
Welding with basic coated electrodes with their relatively low hydrogen content involves less risk of hydrogen induced underbead cracking than if cellulosic electrodes are used. Still, preheating to a temperature of approx. 100 C (210 F) is recommended, particularly for welding heavy wall pipe from steels that are susceptible to hardening. The diagram illustrates those cases for which preheating is recommended.
0.20 Preheating Carbon content (%)

0.10 No preheating or only for the purpose to eliminate condensed water (mm) 5 (inch) 3/16 Wall thickness 10 3/8 15 19/32 20 25/32 25 1

Preheating depending upon wall thickness and carbon content.

18

1/3

Basic coated electrodes

In cases where extra high toughness is required, extreme climatic conditions, heavy wall pipes ( 25 mm / 1 inch) e.g. Iandfall sections or the highest strength pipe steels StE 550.7 TM/X 80, X 100 there is a demand for low hydrogen vertical down electrodes. BHLER WELDING offers four different grades matching all of the important requirements including the practical and economical demands in field welding large diameter pipelines.

Comparison of impact strength

Diagram no. 1 indicates the impact strenght behaviour of vertical down welded joints and shows that the basic coated deposit is clearly tougher. The fact that the weld metal toughness of our of cellulose coated electrodes has improved considerable is shown with the example of FOX CEL 85 (E8010-P1). Diagram no. 2 gives an overview about the excellent economical benefits when welding filler and cover passes with basic coated vertical down electrodes.

Iow hydrogen vertical down electrodes have approximately the same deposition rate as 5.5 mm (7/32") diameter cellulose electrodes. Therefore the time required for the welding of filler and cover passes is similar using cellulose or basic coated vertical down electrodes. However, there are losses in economy when welding the root pass with basic coated vertical down electrodes. It is therefore recommended and widely practiced, that root and hot passes be welded with cellulose coated electrodes, and filler and cover passes with basic coated vertical down electrodes. It is thus possible to combine high economy with good mechanical-technological values in the joint weld. A great deal of experience has been gained already using this technology with very positive results. Should you require further details please contact our Technical Department.
Diagram no. 2 2.6

Combined technology with cellulose and basic coated electrodes

Due to the high iron powder content of the basic coating and the ability to weld with high currents, 4 mm (5/32") diameter
Diagram no. 1 Single V butt joint, API X 60, 20 mm vertical down Basic coated AWS E8018-G

2.4 2.2

160 140 120 100 Charpy - V impact energy in Joule 80

basic coated 5G down 4.5 mm cellulosic 5G down 5 mm basic coated 5G up 4 mm

2.0 1.8

New generation AWS E8010

1.6 1.4 1.2 1.0 Desposition rate in kg/h

60 40 20 0 -60 -20 -40 Test temperature in C +0 +20

0.8 0.6 0.4 0.2 0 160 140 Welding current in A 180 200 220 240

BHLER WELDING Consumables for pipeline construction

19

Welding technology

D.C. positive 2.5 mm (3/32) 70 - 90 A In welding position 10 - 14 oclock 60 - 70 A 3.2 mm (1/8) 90 - 150 A In welding position 10 - 14 oclock 90 - 100 A

Stringer bead or root pass

All available grades of line pipe steels can be welded with BHLER FOX BVD RP if root pass welding with cellulosic electrodes is not permitted. It has become general practice to have two or more welders work simultaneously in order to reduce distortion and maintain uniform gap width. The recommended electrode diameter is 2.5 mm (3/32") or in the case of heavy walled large diameter pipes also 3.2 mm (1/8"). Maintain direct contact with the bevel faces. Grinding of the end crater should be carried out. In order to avoid a change in the slag viscosity and to maintain excellent control of the slag, groove faces must be free from foreign matter such as scale or rust.

Start: 12 oclock

80 - 90

Stop: 7 oclock

Short arc! Keep direct contact!

To prevent any porosity it is necessary to avoid any keyhole formation during welding. Too high a current could cause this problem. One should never finish root passes welded from two sides in 6 o'clock position. Termination of the runs should be approximately in the 7 o'clock position only. It is recommended to operate the electrode with a short arc. Remove slag from each bead by grinding. A clean slag-free bead assures excellent slag control when welding the subsequent layers with basic coated electrodes.

Avoid: keyhole formation

Correct: no keyhole

Filler passes
These passes are executed with 3.2 mm, 4 mm and 4.5 mm dia electrodes, depending upon plate thickness. A diameter of 4 mm being preferred. 3.2 mm 4 mm 4.5 mm (1/8") (5/32") (3/16") 110 - 160 A 180 - 210 A 200 - 240 A

Grind end craters

The high amperage ensures sufficient penetration and satisfactory economy of the process. Avoid welding without weaving, as this would cause the pool to move faster than the electrode, short-circuiting the arc for a considerable time and making the electrode stick. This has a negative effect on the deoxidation process and favours porosity. Experienced welders will know which weave width and weld speed to choose, also taking into account the slag flow. In the overhead position, width of weaving is limited by manipulation. For welding heavy wall pipe we recommend to deposit 2 to 3 beads side by side, removing all slag before applying a new

Grind root pass

20

Basic coated electrodes

bead. If slag residuals are covered by a new bead, in 3 o'clock position in particular, the whole slag pool will flow ahead of the arc. Keep the arc as short as possible. To avoid any hardening peaks it is recommended that the last filler pass should be flush with the pipe surface so that the edges of the joint preparation are melted. This is to ensure that the capping pass when deposited tempers the heat affected zone.

Start: 12 oclock

80 - 90 80 - 90 11 to 1 oclock + 5 to 7 oclock 60 - 80 for other positions

Cap
The cap is deposited with a slight weaving technique, with a maximum weave of twice the electrode diameter.
Stop: 6 oclock

Recommended amperages: 3.2 mm 4 mm (1/8") (5/32") 110 - 160 A 180 - 210 A

Keep the arc short!

Rules for storage and rebaking of basic coated electrodes

Electrodes which have been stored in sealed cans do not need to be rebaked.
Weave width max. 2 x

Once a can has been opened, the electrodes it contains should be kept in a closed electrode container, until they are used for welding. Electrodes which are taken from unsealed, damaged cans or those which have been kept in open storage for several hours should be rebaked at 300 - 350 C (570 - 660 F) for 2 hours minimum and 10 hours maximum. In the event of rel. air humitity of more than 70 % it is recommended to use heated quivers maintaining a temperature of 100 - 200 C (210 - 400 F) prior to use.

Electrode Stopping the arc

Avoid: direct lifting of electrode

Correct: move downwards and then lift

Avoid: narrow gaps

Correct: Flat beat contours

Leads to slag inclusions

Grind if necessary

BHLER WELDING Consumables for pipeline construction

21

Welding technology Basic coated electrodes

Wall thickness
in. mm

Electrode consumption (kg)

2.5 mm 3/32 inch 0.30 0.20 0.20 0.20 3.2 mm 1/8 inch 4 mm 5/32 inch Total

Wall thickness
in. mm

Electrode consumption (kg)

3.2 mm 1/8 inch 0.20 0.20 0.20 0.20 4 mm 5/32 inch 2.60 3.00 3.40 3.90 Total

11/64 13/64 1/4 5/16 3/8 1/2 5/8 11/16 3/4 13/16 7/8 15/16 1

14.36 15.16 16.35 17.93 19.52 12.70 15.88 17.46 19.04 20.63 22.22 23.81 25.40

0.20 0.35 0.65 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20

0.90 1.55 2.45 2.95 3.50 4.00 4.75 5.40 6.00

0.30 0.40 0.55 0.85 1.10 1.75 2.65 3.15 3.70 4.20 4.95 5.60 6.20

13/16 7/8 15/16 1

20.63 22.22 23.81 25.40

2.80 3.20 3.60 4.10

*) For quantities see Chapter on Form of supply in the individual description of electrode brands.

*) For quantities see Chapter on Form of supply in the individual description of electrode brands. 1 kg = 2.205 pounds (lbs)

60

10

30 1/3 2/3

Trouble shooting

Defects

Causes

How to avoid defects

Start porosity

use of damp electrodes drawing a long arc after ignition use of electrodes with damaged striking tips welding over slag residues insufficient grinding of undercut amperage too low

use only dry (rebaked) electrodes keep the arc short use undamaged electrodes use ignition active BHLER electrodes precise inter run cleaning by grinding or brushing grind sufficiently any undercut increase the amperage

Lack of fusion

Sagging stringer bead

amperage too high electrode diameter too large poor joint preparation root gap too narrow

set a lower amperage use of smaller electrode diameter joint preparation according to recommendation

Striking marks

stray arcing outside joint preparation causes local hardening

strike arc in the groove only

Slag inclusions

insufficient cleaning between passes

clean each layer with rotating wire brush

Scattered porisity

use of damp electrodes prolonged short circuit due to use of welding machines with poor welding characteristics poor electrode manipulation e.g. arc too long, angle incorrect

use only dry (rebaked) electrodes check the welding machine (open circuit voltage etc) handle the electrode correctly e.g. keep the arc short, keep the angle of 80 - 90

22

Gas pipeline X-70, Malaysia

BHLER WELDING Consumables for pipeline construction

23

Recommendations for basic coated vertical up electrodes

Basic coated electrodes

Steel grades API FOX EV Pipe E 7016-1 FOX EV 60 Pipe E 8016-G FOX EV 70 Pipe E 9016-G

A B X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80
Steel grades EN

L210 L245 L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB

for root pass, hot pass and filler passes and capping for root pass welding only

Compared to root pass welding with cellulosic-coated vertical-down electrodes the welder has to face a welding speed reduction of 60-70 % when welding the same root pass with basic-coated vertical-up electrodes. Nevertheless new product developments show a welding behaviour which allows the economic production of joints. BHLER FOX EV Pipe products guarantees significant advantages in positional welding: Usability of a diameter 4.0 mm up to a wall thicknesses equal or above 12 mm. 24

Better and easier operating properties compared to a standard E7018-type. Obvious economic advantages for cap layers. Reduced grinding work compared to E7018 electrodes.

Furthermore these products exhibit high mechanical load capacity, lowest hydrogen contents in deposit, good air gap bridgeability, best thoughness values and highest tensile strength properties (if required).

Basic coated electrodes for vertical up welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals Standard Classification

mm

A EN API

FOX EV PIPE
EN 499:1994 - E 42 4 B 1 2 H5 AWS A5.1-04: E7016-1 H4 R AWS A5.1M-04: E4916-1 H4 R

SMAW

C Si Mn Ni

0.06 Re 0.60 Rm 0.9 A5 0.17 Av +20C: -20C: -40C: -46C:

470 ( 420) N/mm2 560 ( 520-640) N/mm2 29 ( 22) % 170 100 60 55 ( 120) J J ( 47) J ( 27) J

2.0 2.5 3.2 4.0

30-60 40-90 60-130 110-180

TV-D, CL, UDT, LTSS, SEPROZ, VNIIST, VNIGAZ

Polarity negative for root pass. Preheat and interpass temperature as required by the base material. The optimum gap width for root passes is 2-3mm, the root face should be in the range 2-2.5 mm. The electrodes are ready for use straight from the hermetically sealed tins. Re-drying if necessary: 300-350 C, min. 2 h.

YS 68000 ( 61000) PSI TS 81200 ( 74000-92800) PSI Elongation on 4d 29 ( 22) % Impact energy +68F: 125 ( 89) ft-lb -4F: 74 ft-lb -40F: 44 ( 35) ft-lb -51F: 40 ( 20) ft-lb

BHLER FOX EV PIPE is a basic coated electrode with some additions of rutile and silicates. It is excellent suited for positional welding of root passes using D. C. negative polarity as well as for filler and cover passes of pipes, tubes and plates on D. C. positive polarity, or even AC. BHLER FOX EV PIPE offers considerable time savings against AWS E 7018 type electrodes when welding root passes due to increased travel speeds. Also the use of dia. 3.2 mm is possible for root passes in case of wall thicknesses of 8 mm and more. It is user friendly and provides a good gap bridging ability together with easy slag removal to ensure minimum grinding. Weld metal toughness is available down to -46C; very low hydrogen content (HD < 5 ml/100 g).

P235GH, P265GH, P295GH, P235T1, P275T1, P235G2TH, P255G1TH, S255N-S420N1), S255NL1 up to S420NL1, L290NB up to L360NB, L290MB up to L415MB, L450MB2) up to L555MB2) API Spec. 5 L: A, B, X42, X46, X52, X56, X60, X65-X802) ASTM: A53 Gr.A-B, A106 Gr.A-C, A179, A192, A210 Gr.A-1
1)

stress relieved up to S380N / S380NL1 only for root pass

2)

FOX EV 60 PIPE
EN 499:1994 E 50 4 1 Ni B 1 2 H5 AWS A5.5-96: E8016-G H4 R

SMAW

C Si Mn Ni

0.07 Re 0.60 Rm 1.2 A5 0.9 Av +20C: 0C: -20C: -40C:

550 ( 500) N/mm2 590 (560-720) N/mm2 29 ( 22) % 170 150 140 110 ( 130) J J J ( 47) J

2.5 3.2 4.0 5.0

40-90 60-130 110-180 180-230

VNIIGAZ

Polarity negative for root pass. Preheat and interpass temperature as required by the base material. The optimum gap width for root passes is 2-3 mm, the root face should be in the range 2-2.5 mm. The electrodes are ready for use straight from the hermetically sealed tins. Re-drying if necessary: 300-350 C, min. 2 h.

YS 80000 ( 72500) PSI TS 85600 ( 81200-104400) PSI Elongation on 4d 29 ( 22) % Impact energy +68F: 125 ( 96) ft-lb +32F: 111 ft-lb -4F: 103 ft-lb -40F: 81 ( 35) ft-lb

Basic coated electrode excellent suited for positional welding of root passes using D.C. negative polarity as well as for filler and cover passes for pipes, tubes and plates on D.C. positive polarity, or even A.C. BHLER FOX EV 60 PIPE offers considerable time savings against AWS E 8018 type electrodes when welding root passes due to increased travel speeds. Also the use of dia. 3.2 mm is possible for root passes in case of wall thikknesses of 8 mm and more. Good impact properties down to -40 C, low hydrogen content (HD < 5 ml/100 g), as well as packaging in hermetically sealed tins are further features for the user.

S235J2G3-S355J2G3, L210NB-L450NB, L210MB-L450MB, P235GH-P295GH, E295, E335, S355J2G3, C35-C45, P310GH, S380N-S460N, P380NH-P460NH, S380NL-S460NL, S380NL1-S460NL2, GE260-GE300 API Spec. 5 L: X42, X46, X52, X56, X60, X65 ASTM: A516 Gr.65, A572 Gr.55,60,65, A633 Gr.E, A612, A618 GrI, A537 Gr.1-3

FOX EV 70 PIPE
EN 757:1997
E 55 4 Z (Mn2NiMo) B 1 2 H5

SMAW

C Si Mn Ni Mo

0.06 0.50 1.7 2.2 0.3

Re Rm A5

620 ( 550) N/mm2 680 (630-780) N/mm2 20 ( 18) %

2.5 3.2 4.0

40-90 60-130 110-180

AWS A5.5-96: E9016-G H4 R

Av +20C: 140 ( 90) J -20C: 80 J -40C: 70 ( 47) J YS 90000 ( 80000) PSI TS 98600 ( 91300-113100) PSI Elongation on 4d 20 ( 18) %

BHLER FOX EV 70 PIPE is a high strength basic coated electrode. It is excellent suited for positional welding of root passes using D. C. negative polarity as well as for filler and cover passes of pipes, tubes and plates on D. C. positive polarity, or even AC. BHLER FOX EV 70 PIPE offers considerable time savings against AWS E9018 type electrodes when welding root passes due to increased travel speeds. Also the use of dia. 3.2 mm is possible for root passes in case of wall thicknesses of 8 mm and more. It is user friendly and provides a good gap bridging ability together with easy slag removal to ensure minimum grinding. Good impact properties down to -40 C, low hydrogen content (HD < 5 ml / 100 g), as well as packaging in hermetically sealed tins are further features for the user.

L450MB, L485MB, L555MB API Spec. 5 L: X65, X70, X80

Polarity negative for root pass. Preheat and interpass temperature as required by the base material. The optimum gap width for root passes is 2-3 mm, the root face should be in the range 2-2.5 mm. The electrodes are ready for use straight from the hermetically sealed tins. Re-drying if necessary: 300-350 C, min. 2 h.

Impact energy +68F: 103 ( 66) ft-lb -4F: 59 ft-lb -40F: 52 ft-lb

BHLER WELDING Consumables for pipeline construction

25

Recommendations for automatic welding with solid wires

Solid wires
Steel grades API SG 3-P ER 70S-6 K-Nova Ni ER 80S-G NiMo 1-IG ER 90S-G

X 42 X 46 X 52 X 56 X 60 X 65 X 70 X 80
Steel grades EN

L290MB L320M L360MB L385M L415MB L450MB L485MB L555MB

for root pass, hot pass and filler passes and capping

BHLER wire for Pipeline welding are especially intended for the needs of semiautomatic and automatic root, hot, fill and cap passes welding on cross-country pipelines. They show on excellent mechanical properties, clean weld deposit, and uniform bead shape. The wires are suited for use on API 5L X42 through X80 pipes.

26

Wires for automatic pipeline welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals Standard Classification

mm

A EN API

SG 3-P
EN 440:1995 G4Si1 EN 440: G 46 5 M G0 G4Si1 G 42 4 C G0 G4Si1 AWS A5.18-01: ER70S-6 AWS A5.18M-01: ER485S-6

GMAW

C Si Mn Ti

0.05 as welded Ar +15-25 % CO2 0.75 510 ( 470) N/mm2 1.5 Re Rm 640 (600-680) N/mm2 + A5 25 ( 24) %2 Av +20C: 120 ( 100) J -40C: 75 ( 65) J -50C: 55 ( 47) J YS 74000 ( 68000) PSI TS 92800 ( 87000-98600) PSI Elongation on 4d 25 ( 24) %

0.9

TV-D, UDT

BHLER SG 3-P is a micro alloyed GMAW solid wire designed for high quality automatic welding of pipelines. An optimum balanced alloying concept ensures good weld metal properties to fulfil the high requirements in the OnOffshore-Pipeline Industry. Deposit is extremely crack resistant and the weld metal toughness is available down to -50 C. The very important quality aspects, prerequisite for uninterrupted feedability of the solid wire e.g. helix of the wire, copper coating, close wire diameter tolerance and precision layer wound spooling are taken into account during the production.

L290MB-L485MB API Spec. 5 L: X42, X46, X52, X56, X60, X65

Shielding gases: Ar +15-25 % CO2 100 % CO2 Preheating and interpass temperature as required by the base metal.

Impact energy +68F: 89 ( 74) ft-lb -40F: 55 ( 48) ft-lb -58F: 40 ( 35) ft-lb as welded Ar +15-25 % CO2 Re Rm A5 470 ( 440) N/mm2 610 (570-640) N/mm2 26 ( 25) %

Av +20C: 100 ( 95) -40C: 60 ( 47) YS 68000 ( 63800) PSI TS 88400 ( 82600-92800) PSI Elongation on 4d 26 ( 25) % Impact energy +68F: 74 ( 70) ft-lb -40F: 44 ( 35) ft-lb

BHLER K-Nova Ni GMAW

EN 440: G3Ni1 AWS A5.28-96: ER80S-G

C Si Mn Ni Ti

0.06 0.70 1.50 0.90 +

as welded Ar +15-25 % CO2 Re Rm A5 500 N/mm2 590 N/mm2 24 %

0.9 1.0 1.2

DNV

Av +20C: 150 J -50C: 80 J Shielding gases:

Ar +15-25 % CO2 Ar +0-5 % CO2 + 3-10 % O2 100 % CO2

YS 72000 PSI TS 85000 PSI Elongation on 4d 24 % Impact energy +68F: 110 ft-lb -58F: 58 ft-lb as welded Ar +15-25 % CO2 Re Rm A5 Av +20C: -50C: 470 N/mm2 560 N/mm2 25 % 110 J 45 J

Micro alloyed GMAW wire designed for high quality automatic welding of pipelines. An optimum balanced alloying concept ensures good weld metal properties to fulfil the high requirements in the OnOffshore pipeline industry. The deposit is extremely crack resistant and the weld metal offers high impact values down to -50 C.

L290MB-L485MB API Spec. 5 L: X42, X46, X52, X56, X60, X65, X70

Preheating and interpass temperature as required by the base metal.

YS 68000 PSI TS 81000 PSI Elongation on 4d 25 % Impact energy +68F: 81 ft-lb -58F: 35 ft-lb

BHLER WELDING Consumables for pipeline construction

27

Wires for automatic pipeline welding

BHLER Standard Operating data

Welding process

Typical Typical analysis mechanical properties %

Sizes

Amperage

Approvals Characteristics and applications

Base metals

mm

NiMo 1-IG
EN 12534:1999 Mn3Ni1Mo (for wire) EN 12534:1999 G 55 6 M Mn3Ni1Mo G 55 4 C Mn3Ni1Mo AWS A5.28-96: ER90S-G

GMAW

C Si Mn Mo Ni

0.08 0.6 1.8 0.3 0.9

as welded Ar +15-25 % CO2 Re Rm A5 620 ( 550) N/mm2 700 (650-800) N/mm2 23 ( 20) %

(0.9) 1.0 1.2

DB, Z, BB, GL, UDT, SEPROZ

Copper coated GMAW wire for high strength, quenched and tempered fine-grained constructional steels. The wire is suited for joint welding in boiler, pressure vessel, pipeline, and crane construction as well as in structural steel engineering. The typical composition of the wire fulfils the requirements of the NORSOK regulation for water injection systems. Due to the precise addition of micro alloying elements NiMo 1-IG wire features excellent ductility and crack resistance in spite of its high strength. Good cryogenic impact energy down to -60 C, low hydrogen contents in the deposit, best feedability and low copper contents are other advantages of this wire.

Pipe steels and fine grained steels, quenched and tempered finegrained steels. S380N-S500N, S380NL-S500NL, S500NC-S550NC, N-A-XTRA 56-70, BHV 70, PAS 600, HSM 600, 20MnMoNi5-5 ASTM: A517 Gr.A,B,C,E,F, H,J,K,M,P; A225 Gr.C, A633 Gr.E, A572 Gr.65 API Spec. 5 L: X70, X80

Av +20C: 140 ( 120) J -40C: 110 ( 90) J -60C: ( 47) J YS 89900 ( 80000) PSI TS 101500 ( 94000-116000) PSI Elongation on 4d 23 ( 20) %

Shielding gases: Ar +15-25 % CO2 Ar +0-5 % CO2 +3-10 % O2 100 % CO2 Preheating and interpass temperature as required by the base metal.

Impact energy +68F: 103 ( 89) ft-lb -40F: 82 ( 66) ft-lb -94F: ( 35) ft-lb as welded Ar +15-25 % CO2 Re Rm A5 590 ( 550) N/mm2 680 (620-770) N/mm2 22 ( 20) %

Av +20C: 120 ( 100) -40C: ( 47) YS 85500 ( 63800) PSI TS 98600 ( 89900) PSI Elongation on 4d 22 ( 25) % Impact energy +68F: 89 ( 74) ft-lb -40F: ( 35) ft-lb

28

Other consumables for pipeline welding

BHLER

Welding process

Typical analysis %

Typical mechanical properties N/mm2 (KSI)

Sizes

Amperage

Approvals Characteristics and applications

AWS EN

mm

FOX CEL S
E6010

GMAW

C 0.10 Si 0.20 Mn 0.50

Re Rm A5 Av

480 550 23 110

(70) (80) % J

2.5 3.2 4.0

Cellulosic electrode especially designed for vertical up welding of root passes on D.C. positive polarity. Can be used however, also vertical down and on negative polarity. Ideally suited for the Dolly Mix technique. It shows a forceful arc and good operating characteristics.

FOX CEL 75 G
E7010-G

GMAW

C 0.14 Si 0.10 Mn 0.7 Ni 0.6

Re 460 (68) Rm 550 (80) A5 24 % Av 110 J -40C: 65 J

3.2 4.0 5.0

Bhler FOX CEL 75 G is an AWS E7010-G cellulose coated electrode for welding the pipe grades X 56, X 60 and X 65 or the EN steels L385M, L415MB and L450MB. The electrode provides consistently high quality as well as outstanding low temperature toughness values together with superior operating characteristics.

FOX CEL 85 G
E8010-G

GMAW

C Si Mn Ni

0.16 0.4 0.7 0.7

Re Rm A5 Av -40C:

490 570 23 105 70

(71) (82) % J J

3.2 4.0 5.0

Bhler FOX CEL 85 G is an AWS E8010-G cellulosic electrode for welding the pipe grades X 60 through X 70 or the EN steels, L415MB, L450MB and L485MB. The electrode provides consistently high quality as well as outstanding low temperature toughness values together with superior operating characteristics.

FOX EV 50-W
E7016-1 H4 R E 42 5 B 1 2 H5

SMAW

C 0.07 Si 0.5 Mn 1.1

Re Rm A5 Av

460 560 28 200

(67) (81) % J

2.5 3.2 4.0

40-60 55-85 80-140 110-180 180-230

TV-D, CL, FI, GL, UDT, LTSS, PDO, SEPROZ

Low hydrogen electrode for compressor station or pressure reduction construction. Excellent for root passes in the vertical up position. It has a very stable penetration arc and gives good X-ray quality welds. Best root welding characteristics on D.C. negative polarity. HD < 5 ml/100 g.

FOX CN 22/9 N
E2209-17 E 22 9 3 N L R 3 2

SMAW

C 0.03 Si 0.9 Mn 0.8 Cr 23.0 Ni 9.0 Mo 3.2 N 0.17 PREN 35

Re 650 Rm 820 A5 25 Av 55 -20C 32

(94) (118) % J J

2.5 3.2 4.0 5.0

40-75 70-120 110-150 150-200

TV-D, TV-A, ABS, CL, DNV, GL, LR, RINA, Statoli, UDT, SEPROZ

Rutile basic coated alloyed-core wire electrode for the welding of ferritic-austenitic duplex steels e.g. 1.4462, UNS 31803. Highly recommended for vertical up welding of tubes and pipes (electrode diameter 2,5 mm; D.C., electrode negative). Good weldability on A.C.

FOX CN 22/9 N-B

E2209-15 E 22 9 3 N L B 2 2

SMAW

C 0.03 Si 0.3 Mn 1.1 Cr 23.0 Ni 8.8 Mo 3.2 N 0.16 PREN 35

Re Rm A5 Av -60C

630 830 27 105 40

(92) (121) % J J

2.5 3.2 4.0 5.0

50-75 80-110 100-145 140-180

TV-D, UDT, CL

Basic coated DUPLEX electrode for UNS S31803. The weld deposit shows excellent impact properties down to -60 C and assures safe welding of heavy wall thicknesses under high requirements. The Pitting Resistance Equivalent is 35 (PREN = % Cr + 3,3 x % Mo + 16 x % N) the ferrite content of the weld deposit is 30 FN.

CN 22/9 N-IG
ER2209 W 22 9 3 N L G 22 9 3 N L

GTAW GMAW

C 0.015 Si 0.4 Mn 1.7 Cr 22.6 Mo 3.2 Ni 8.8 N 0.15 PREN 35

Re Rm A5

GTAW: 600 (87) N/mm2 800 (116) N/mm2 33 %

1.6 2.0 2.4 3.2

Av 150 J -60C 32 J Re Rm A5 GMAW: 660 (95) N/mm2 830 (120) N/mm2 28 % 1.0 1.2

TV-D, TV-A, ABS CL, DNV, GL, LR, Statoil, UDT TV-D, TV-A, CL, DNV, GL, Statoil, UDT, SEPROZ

TIG welding rod and GMAW wire highly suitable for welding ferriticaustenitic duplex steels, e.g. 1.4462, UNS 31803. The metallurgical design of CN 22/9 N-IG with an optimum alloying composition and closest tolerance limits ensure particularly good weld metal properties & resistance to stress corrosion cracking and pitting. it is ideally suited for the high quality requirements in pipeline welding. Best results can also be obtained with our SAW wire CN 22/9 N-UP and flux BB 202.

Av 85 J -40C 32 J

CN 22/9 PW-FD
E2209T1-4 E2209T1-1 T 22 9 3 N L P M 1 T 22 9 3 N L P C 1

FCAW

C 0.03 Si 0.8 Mn 0.9 Cr 22.7 Mo 3.2 Ni 9.0 N 0.13 PREN 35

Re Rm A5

600 (87) N/mm2 800 (116) N/mm2 27 %

1.2

100-220

Av 80 J -46C 45 J

TV-D, DNV, CL, ABS, LR, UDT, GL, RINA, CWB

Flux cored wire for positional welding. Easy to operate in all weld positions with one single parameter setting using Argon mixtures or CO2. Powerful penetrating arc, spray transfer, minimum spatter formation, self releasing slag, excellent wetting behaviour, flat and smooth bead profile. Fast travel speeds and a wide range of operating parameters offer highest productivity. Suitable for service temperatures from -46 C to 250 C.

12 BHLER WELDING Consumables for pipeline construction

29

Details regarding the nature and application purposes of our products are intended for the information of the user. The data concerning the mechanical properties always refers to the all weld metal deposit in accordance with the applicable standards. In the area of the weld joint, the weld metal properties are influenced by the base metal, the welding position and the welding parameters. A guarantee of the suitability for a specific type of application requires in each individual case an implicit agreement in writing. Subject to change without notice.

BHLER WELDING Consumables for pipeline construction

31

Published by BHLER WELDING

Bhler Schweitechnik Austria GmbH Bhler-Welding-St. 1 8605 Kapfenberg / AUSTRIA +43 (0) 3862-301-0 +43 (0) 3862-301-95193 postmaster.bsga@bsga.at www.boehler-welding.com Member of the BHLER-UDDEHOLM Group

BSGA 06/2005 E1000 Cover picture: STEAG

Your partner: